Stair tread pan design with bolt-in pre-cast concrete/other material tread capability

ABSTRACT

A stair tread pan includes a plurality of stair risers, each of the plurality of stair risers comprising a uniform depth and width, whereby the stair tread pan consistently satisfies code requirements. The stair tread pan further comprising predetermined assembly tolerances are less than approximately ½ inch for drainage of the stair tread pan in an exterior use. The stair tread pan comprises at least one tread nosing formed into the stair tread pan for yielding a uniform for reliable and durable tread nosing. The stair tread pan further comprising a poor stop at a top end of the stair tread pan for receiving poured concrete, thereby illuminating the need for tea-bars or other concrete containing structures for forming a top landing on the stair tread pan. The the stair tread maybe read a leap replaced without disturbing the structured integrity outside stair tread pan in a building environment.

FIELD OF THE INVENTION

The present disclosure relates to steel building structures and methods of formation and use. The disclosure further relates to a method and systems for stair tread pan design with bolt-in pre-cast concrete/other material tread capability.

BACKGROUND

The application provides pre-tread and post-tread installs for pre-cast concrete treads with formed riser pans that provide the technical advantages of providing a pre-fabricated stair system that can be installed and used at the construction site during construction without installation of temporary tread material or the final installation of concrete treads thus being able to use a set of stairs during construction without putting the pre-cast concrete tread in. This prefabricated design allows instant access for construction trades and building inspectors without damaging the finished product.

SUMMARY

In contrast to prior methods and systems the disclosed subject matter of the stair tread pan design eliminates the need for temporary stair tread material or for placing the concrete stair treads during the construction of the other building parts thus avoiding damage to the finished stair treads or damage to temporary stair tread material. The stair tread pan design allows for a simple, safe work surface for tradesmen, building inspectors and others to access the stairway during construction. Other systems require the installation of the pre-cast concrete tread or other temporary material to create a safe and walkable surface. Without this additional step(s) the stairs would either not be function and/or safe. The installation of the pre-cast tread during construction typically results in damage to the tread or requires additional materials to protect the treads during the construction phase.

Further technical advantages include the following:

a. The stair tread pan design is pre-fabricated in the shop to allow for uniformity in riser height and tread depth and width with minor tolerances allowed for on-site installation. The design allows for a consistent control of the riser height using the sheet metal which keeps the stair code compliant.

b. The design also allows for tolerances in the shop fabrication process allowing for production style assembly.

c. The stair tread pan design allows for some assembly tolerances via the space between the pans. This is kept to a minimum (typically one-half inch). This space between the pans allows for drainage which is important as most of these stair systems are used as exterior egress stairs.

d. The split pan design with minimal spacing also provides additional support to the pre-cast treads or other material treads and could allow the possibility to design a lighter tread used in combination with the pan to meet load requirements.

e. The nosing of the tread is built into the pan design and not into the separately installed tread thus making it more uniform, reliable and durable.

f. The top stair of the stair tread pan design assembly serves as a pour stop for the landing at the top of the stair which is typically poured concrete. This special feature allows the elimination of the use of T-bars or other products such as temporary materials to contain the landing concrete when poured.

g. The stair tread pan design assembly allows treads to replaced easily if desired for any reason or if damage occurs to the tread at a later time. The tread can be unbolted easily from the stair tread pan assembly and a new tread placed and bolted through the pre-cut bolt holes without disturbing the structural integrity of the stair tread pan assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the disclosed subject matter may be set forth in any claims that are filed later. The disclosed subject matter itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, may best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is view of the stair tread pan assembly looking down on the walkable tread area prior to the final tread being place;

FIG. 2 is view of the stair looking up the stair tread pan assembly demonstrating the controlled riser height;

FIG. 3 is view of the stair tread pan assembly demonstrating the last stair which can be used as a pour stop for the landing area;

FIG. 4 shows a view of the stair tread pan assembly as if walking down the stair demonstrating the minimal spacing (typically one-half inch);

FIG. 5 shows a view of the stair tread pan design assembly looking down showing pre-cut holes that are used to bolt the stair treads into place.

FIG. 6 shows a view of the stair tread pan design assembly with the top riser that can be used as a pour stop for the poured concrete landing;

FIG. 7 displays a view of the stair tread pan assembly showing consistent and uniform riser heights required by code;

FIG. 8 is a drawing of the stair tread pan design “pre-tread install”;

FIG. 9 is a drawing of the stair tread pan design “post-tread install”;

FIG. 10 is a drawing showing uniform and consistent riser height between 6 inches or 7 inches (can vary depending on design) and the ½ inch gap minimal spacing between formed tread risers;

FIG. 11 shows a drawing of the typical pan sequence showing the one-inch overlap for each tread riser, the typical one-inch pre-cut holes for attaching the tread and the typical one-half inch minimal spacing gap; and

FIG. 12 shows a drawing of the entire stair tread pan assembly design with enhanced sections: section 1 showing the top riser and top pan connection; section 2 showing the intermediate pan connection; and section 3 showing the bottom riser and the bottom pan connection.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same components.

The terminology used herein is for describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It may be further understood that the terms “comprises” and/or “comprising” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the implementations described herein. However, it will be understood by those of ordinary skill in the art that the implementations described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the implementations described herein. Also, the description is not to be considered as limiting the scope of the implementations described herein.

In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific implementations which may be practiced. These implementations are described in sufficient detail to enable those skilled in the art to practice the implementations, and it is to be understood that other implementations may be utilized, and that logical, mechanical, electrical and other changes may be made without departing from the scope of the implementations. The following detailed description is, therefore, not to be taken in a limiting sense.

Here is provided a stair tread pan design with bolt-in pre-cast concrete/other material tread capability allows the pans to be welded in place to the stringers at the fabrication shop (see attached drawing and photographs). The fabricated stair tread pan designed assembly (tread pans and risers) can then be installed quickly and easily at the construction site for immediate use by construction trades to access upper floors of the construction project before treads are installed. This functionality allows use of the stairs before tread installation and prevents damage to the treads during construction work. The treads can be installed by bolting to the stair tread pans through the pre-cut holes. The one-inch pre-cut holes in the pans allow for minor adjustments of the stair tread at installation.

The split plan design allows some assembly tolerance via the space between the pans. The space between the pans also allows for drainage which is important as most of these stair systems are used as exterior egress stairs. The space between the pans is kept to a minimum (typically ½ inch or one-half inch). This minimum spacing allows for quick installation and immediate use of the stair assembly. The minimum spacing eliminates the need for pre-cast tread installation or temporary wood tread installation as is typically required for use of the stairs during project construction.

The split pan design with minimal spacing also provides additional support to the pre-cast concrete treads or other material treads and could allow the possibility to design a lighter tread used in combination with the pan to meet load requirements. The pans of the stair tread pan design meet load requirements for required engineering calculations. The pans of the stair tread pan design can be finished as painted, powder coated or galvanized.

The nosing of the tread is built into the pan design and not into the separately installed tread thus making the it more uniform, reliable and durable.

FIG. 1 is view of the stair tread pan assembly looking down on the walkable tread area prior to the final tread being place;

FIG. 2 is view of the stair looking up the stair tread pan assembly demonstrating the controlled riser height;

FIG. 3 is view of the stair tread pan assembly demonstrating the last stair which can be used as a pour stop for the landing area;

FIG. 4 shows a view of the stair tread pan assembly as if walking down the stair demonstrating the minimal spacing (typically one-half inch);

FIG. 5 shows a view of the stair tread pan design assembly looking down showing pre-cut holes that are used to bolt the stair treads into place.

FIG. 6 shows a view of the stair tread pan design assembly with the top riser that can be used as a pour stop for the poured concrete landing;

FIG. 7 displays a view of the stair tread pan assembly showing consistent and uniform riser heights required by code;

FIG. 8 is a drawing of the stair tread pan design “pre-tread install”;

FIG. 9 is a drawing of the stair tread pan design “post-tread install”;

FIG. 10 is a drawing showing uniform and consistent riser height between 6 inches or 7 inches (can vary depending on design) and the ½ inch gap minimal spacing between formed tread risers;

FIG. 11 shows a drawing of the typical pan sequence showing the one-inch overlap for each tread riser, the typical one-inch pre-cut holes for attaching the tread and the typical one-half inch minimal spacing gap; and

FIG. 12 shows a drawing of the entire stair tread pan assembly design with enhanced sections: section 1 showing the top riser and top pan connection; section 2 showing the intermediate pan connection; and section 3 showing the bottom riser and the bottom pan connection.

According to the architectural dimensions (floor heights and floor openings) desired, the stringer material (typically metal) is cut and laid out with measurements made for the stair tread pans. The material for making the stair tread pan design (typically sheet metal) is cut to size and the holes for the stair tread pans are cut out. The stair tread pan design material is then formed to shape. Once formed to shape, the stair tread pan formed material is placed according to layout measurements with the stringers and welded to form the stair tread pan design assembly. The initial beginning stair is cut differently to conform to the base material of the floor and the top stair pan forms the final riser of the stair and can also be used as a pour stop for the landing material (concrete) which is added later. The gap tolerances built into the stair tread pan design include minimal spacing (typically one-half inch) which allows for ease of assembly at the factory and accommodation to slight variances in fabrication process. The gap is kept minimal

Novel aspects of the present disclosure include the following:

The stair tread pan design allows a pre-fabricated stair system to be installed at the site for immediate use by the construction trades and building officials as compared to a system that require temporary materials to create a walkable and safe surface. The stair tread pan design assembly stair system can be used during the construction phase. The finished treads can be installed at the final stages of building construction thus avoiding damage to the final treads during construction which can typically occur.

The stair tread pan design assembly is formed to ensure consistency in riser height and tread pan depth and width with minimal spacing to allow for tolerances during fabrication. This consistency in dimensions keeps the stair system code compliant.

The stair tread pan assembly has a finished top tread riser that can serve as a pour stop thus eliminating temporary materials to be used to contain the poured concrete when the landing is poured.

The tread structure of the stair tread pan is designed to use a commonly available tread structures that may be manufactured by a variety of manufacturers and out of a variety of materials. This depends on the desire of the user and the construction environment in which the presently disclosed stair tread pan will be used.

Because treads on stairs often times take substantial wear, they need to be replaced from time to time. Because the stair tread pan of the present disclosure accommodates a uniformly X available tread structure, a variety of products and a variety of manufacturers may be used for replacing worn trade structures for different applications.

With the disclosure here provided, the stair tread may be simply detached by removing screws or other fasteners and thereby remove the old warrant tread. After removal New replacement tread may be applied so that the stairs take on our new fresh look according to the desires of the building personnel.

The predetermined fabrication tolerances are sufficiently precise to afford a production style assembly of the stair tread pan. There is a commonality in the stairs. So, whether one staircase or many staircases are being developed or manufactured, the tolerances and standards are the same. In fact, when multiple staircases are being used, the components necessary for the stair tread pan can be used can be manufactured item by item and then assembled into the stair tread pan. The presently disclosed assembly process allows extensive automation of the stair tread pan manufacturing process, as well as automation and standardization in the installation of the stair tread pan for the different building environments in which it has application.

For example, one part of the stair tread pan may be the stringers. Another part may be the risers, another may be the run, there may be other components but the ability to manufacture. All of these components may be separately and uniformly made. Then, they may be assembled into the presently disclosed stair tread pan. This makes the system of the present disclosure much more economically practical and generally better for the applications intended. For example, in a given sterile tread pan, there may be a particular riser for the top stair and a particular riser for the bottom stair. All the stairs in between the top and the bottom may be identical and may be associated in form together in a uniform configuration.

Thus, for example, in the construction of a 10-story building. There maybe 10 stair tread pans desired for connecting the different stories of the building using the stairs. The stairs may be constructed using 10 unique top stairs and 10 bottom stairs, with 10 risers therebetween for each of the 10 sets of stair tread pans. Thereafter, all of the stairs risers and runs in between then, each of the 10 stair tread pans, may be assembled at the fabrication facility. These may be then transported to the 10-story building construction site. There, they may be installed as necessary to connect the different floors. By virtue of all of the 10 stairs in this scenario being identically formed, there are potentially significant cost savings that are useful in the formation of metal and concrete stairs. Because of the design of the present disclosure it is possible to make all of the stair configurations in a single production run for a given building, such as the 10-story building.

The stair tread pan provides the additional benefit of providing sufficient structure so that many different materials for the stairs may be used. The sheet metal itself creates a flat deck upon which you can put any type of the builder may install any type of material for structurally or aesthetically completing the stairs. The sheet-metal itself provides for the step platform for the newly constructed stairs. The sheet-metal provides an attractive uniform surface capable of accommodating many different types of materials. This may include wood, concrete, linoleum tile or other materials for making an aesthetically attractive landing for a staircase. Another aspect

Another aspect of the present disclosure is that by virtue of using the pre-fabricated stair tread pan, a lighter stairway may be formed that has a variety of uses in a variety of building scenarios. Many of the available scenarios for use of the stair tread pan might be quite different from conventional concrete or steel stairs. This increases the flexibility of design when using the presently disclosed stair tread pan. This, for example, may include a wide variety of load requirements that a concrete or steel staircase may not be able to accommodate. A steel separately-constructed staircase may not be able to accommodate such loads and installation requirements.

A special and different aspect of the stair tread pan of the present disclosure includes a different opportunity than original precast concrete stairs. With the conventional pre-fabricated concrete stairs, there is no structural support between the stairs in the staircase. This is the way that precast concrete stairs work in a precast concrete staircase. In order to hold the load of individuals walking up and down stairs, the only thing that supports the walker is the pre-precast tread.

With the stair tread pan of the present disclosure, there is structural support all the way across the stairs. From front to back with a small gap and side to side from stringer to stringer there is significantly more support in the presently disclosed stair tread pan.

With the metal also supporting the tread as with the presently disclosed tread stair tread pan, the tread itself does not need to provide sufficient engineering support for use in a metal staircase. Thus, a number of options are now available for use of materials and forms and supplying the tread that may be used in the staircase.

As a result of the construction of the present stair tread pan, with a lighter and stronger form, a number of engineering design options are available. For example, concrete treads in a conventional staircase may weigh 100 to 120. During construction, these treads must be lifted and installed manually by the construction team. This is a completely manual process. Moreover, because of the weight considerations, the number of conventional concrete tread's that may be used is limited given particular truck loading tolerances. As an example, if a particular construction draw job requires 1000 concrete tread's, and a truckload limitation is 400 concrete treads. This load limitation results in a construction limitation for a particular construction crew.

As a result of the stair tread pan construction here disclosed, the lighter transport lighter and lighter installation considerations significantly increase the flexibility of construction crews and construction options for a building contractor. This will increase construction speed and reduce construction cost. Moreover, because of the fact that the reduction or illumination of individual concrete trades for staircases, which must be manually moved, injuries to construction workers can be significantly reduced, as well.

By virtue of the presently disclosed stair tread pan being able to be constructed as a single integrated stairway with light or construction that is more portable and that can accommodate a different type of stair tread's, there are significantly greater construction opportunities and variations that the presently disclose system before this. As a result of the lighter and stronger materials, the engineering calculations in order for stairway to comply with building code requirements will be more easily and more cost-effective cost-effectively satisfy. By virtue of the ability to ship more units and reduce construction cost, reduce shipment cost, construction cost as a whole will be substantially reduced to using the presently disclosed stair tread pan system.

Another aspect of the presently disclose system is that the stair tread pan provides the ability to have many more aspects of the stair construction be standardized and constructed prior to leaving the fabrication facility. With the ability to pre-construct staircases at the fabrication facility, it is possible to have specific information about the weight and engineering tolerances of the newly constructed staircases. With all engineering constructions with all engineering construction parameters completed prior to the transport of the stair tread pan leaving the fabrication facility, engineering certifications can much can be much more readily achieved.

With more quickly, reliably and uniformly derived engineering certifications for installation of a stair tread pan add a construction site then here to four possible, cost associated with engineering certification of a building site can also be reduced. This will permit engineers who must make the certifications more productive and the results of such certification much more reliable and much more readily achieved.

In the traditional structural steel fabrication, staircases are built according to the particular plans for the building. With the stair tread pan of the present disclosure, however, the stair tread pan may be formed at the fabrication facility according to the specific engineering plans for the building. Then, the fabricated stair tread pan may be transported to the construction site. By virtue of being able to fabricate at the facility and then transport to the fabricated stair tread pan to the facility, the engineering calculations and certifications can be derived at the facility as appropriate. Then, once the stair tread pan is installed, any remaining engineering certifications necessary for the construction of the building can be finished on site.

The presently disclose stair tread pan is a pre-engine pre-engineered product useful for writing a wide variety of construction applications. Thus, in certifying that the stair tread pan is appropriately used it for construction site, an engineer will be required to confirm the air proper installation, in most cases. Yet, this use of engineering talent maybe substantially less than that which is required for tradition steel staircase installation is not manufactured as described here within the present disclosure. Because the engineer can rely upon the standardization of the stair tread pan fabrication process and the repeatability of the steps there between, the certification has been improved.

The reliability of the stairwell using the stair tread pan improve with greater flexibility and strength. The predetermined fabrication tolerances are sufficiently precise to afford a production style assembly of the stair tread pan. There is a commonality in the stairs. So, whether one staircase or many staircases are being developed or manufactured, the tolerances and standards are the same. In fact, when multiple staircases are being used, the components necessary for the stair tread pan can be used can be manufactured item by item and then assembled into the stair tread pan

As a result of the stair tread pan construction here disclosed, the lighter transport lighter and lighter installation considerations significantly increase the flexibility of construction crews and construction options for a building contractor. This will increase construction speed and reduce construction cost. Moreover, because of the fact that the reduction or illumination of individual concrete trades for staircases, which must be manually moved, injuries to construction workers can be significantly reduced, as well.

By virtue of the presently disclosed stair tread pan being able to be constructed as a single integrated stairway with light or construction that is more portable and that can accommodate a different type of stair tread's, there are significantly greater construction opportunities and variations that the presently disclose system before this.

As a result of the lighter and stronger materials, the engineering calculations in order for stairway to comply with building code requirements will be more easily and more cost-effective cost-effectively satisfy.

By virtue of the ability to ship more units and reduce construction cost, reduce shipment cost, construction cost as a whole will be substantially reduced to using Lisa present leaves disclosed stair tread pan system.

Another aspect of the presently disclose system is that the stair tread pan provides the ability to have many more aspects of the stair construction be standardized and constructed prior to leaving the fabrication facility. With the ability to pre-construct staircases at the fabrication facility, it is possible to have specific information about the weight and engineering tolerances of the newly constructed staircases. With all engineering constructions with all engineering construction parameters completed prior to the transport of the stair tread pan leaving the fabrication facility, engineering certifications can much can be much more readily achieved.

With more quickly, reliably and uniformly derived engineering certifications for installation of a stair tread pan add a construction site then here to four possible, cost associated with engineering certification of a building site can also be reduced. This will permit engineers who must make the certifications more productive and the results of such certification much more reliable and much more readily achieved.

The presently disclose stair tread pan is a pre-engine pre-engineered product useful for writing a wide variety of construction applications. Thus, in certifying that the stair tread pan is appropriately used it for construction site, an engineer will be required to confirm the air proper installation, in most cases. Yet, this use of engineering talent maybe substantially less than that which is required for tradition steel staircase installation is not manufactured as described here within the present disclosure. Because the engineer can rely upon the standardization of the stair tread pan fabrication process and the repeatability of the steps there between, the certification has been improved. And the reliability of the stairwell using the stair tread pan improve with greater flexibility and strength.

In summary, the present disclosure provides a stair tread pan, comprising a plurality of stair risers, each of the plurality of stair risers comprising a uniform depth and width, whereby the stair tread pan consistently satisfies code requirements. The stair tread pan further comprising predetermined assembly tolerances are less than approximately ½ inch for drainage of the stair tread pan in an exterior use. The stair tread pan comprises at least one tread nosing formed into the stair tread pan for yielding a uniform for reliable and durable tread nosing. The stair tread pan further comprising a poor stop at a top end of the stair tread pan for receiving poured concrete, thereby illuminating the need for tea-bars or other concrete containing structures for forming a top landing on the stair tread pan. Further whereby he the stair tread maybe read a leap replaced without disturbing the structured integrity outside stair tread pan in a building environment. The stair tread pan includes predetermined assembly tolerances are sufficiently precise for production style assembly of the stair tread pan. The stair tread pan provides predetermined assembly tolerances that are sufficiently small for providing additional support for pre-cast treads and material treads and for satisfying a plurality of predetermined load requirements.

The embodiments described above are exemplary and are not to be taken as limiting in any way. They are merely illustrative of the principles of the disclosure. Various changes, modifications and alternatives will be apparent to one skilled in the art. Accordingly, it is intended that the art disclosed shall be limited only to the extent required by the appended claims and the rules and principles of applicable law. 

We claim:
 1. A stair tread pan, comprising: a plurality of stair risers, each of said plurality of stair risers comprising a uniform depth and width, whereby said stair tread pan consistently satisfies code requirements; said stair tread pan further comprising predetermined assembly tolerances are less than approximately ½ inch for drainage of said stair tread pan in an exterior use; and wherein said stair tread pan comprises at least one tread nosing formed into said stair tread pan for yielding a uniform for reliable and durable tread nosing; said stair tread pan further comprising a poor stop at a top end of said stair tread pan for receiving poured concrete, thereby illuminating the need for tea-bars or other concrete containing structures for forming a top landing on said stair tread pan; and further whereby he said stair tread maybe read a leap replaced without disturbing the structured integrity outside stair tread pan in a building environment.
 2. The stair tread pan of claim 1, wherein said predetermined assembly tolerances are sufficiently precise for production style assembly of said stair tread pan.
 3. The stair tread pan of claim 1, wherein said predetermined assembly tolerances are sufficiently small for providing additional support for pre-cast treads and material treads.
 4. The stair tread pan of claim 1, wherein said predetermined assembly tolerances are sufficiently small for permitting a lighter tread for satisfying a plurality of predetermined load requirements. 